In the crude oil industry, the Dryvac technology is most useful in applications such as: recycling invert oil drilling fluids, separating mature fine tailings from pond water and weathered bitumen, refining off spec or slop bitumen/oil, recycling of spent lime from SAGD operations, cleaning tank bottoms, drying water based drilled cuttings, or processing product just prior to an upgrader or refinery.
Invert Oils contained in drill cuttings are considered a waste product. The high cost to the customer to store or dump this material in a specialized landfill is non-recoverable. The DryVac process will recover this valuable material for reuse, which means a potential savings of 50% to 75% per hole.
The DryVac System has been successfully employed to filter / dewater and dry lime sludge for oil operations. DryVac successfully dried material for Unocal to decommission lime ponds. When DryVac entered the world of SAGD, lime treatment was one of the first apparent uses for the system. Currently water treatment for SAGD operations rely on a constant train of new lime product and disposal of lime slurry, this disposed material contains valuable products, process water and lime material that can be reused.
Lime sludge when processed through a DryVac was dried to 80% and subsequently reused as a flocculent. The water was returned as process quality. The estimated potential reuse was at 10 times. This gives a potential reduction in lime purchase of 90%. It would also eliminate the need for ponds which are costly to build, maintain and take up much needed space.
The DryVac System has been successfully used to produce <0.05 BS&W from off spec oil (OSO) and diluent OSO.
The DryVac System placed on site is the simplest system to process OSO and eliminate the loss of product (through waste haulage) and the elimination off-spec fees without extensive and costly handling. During recent trials off spec material processed through the DryVac always met a BSW of <0.05.
The DryVac System can also process start up OSO from the first 60 days of a new production well, which was slated for removal to a disposal well. The DryVac System processes this material to the same <0.05 BS&W standard. The oil recovered by the DryVac process is a significant monetary asset, instead of a high cost disposal liability.
The DryVac System can serve many functions in a refinery.
The System is well suited for treatment of the waste effluent stream for the recovery of process water and the minimization of lagoon or discharge buildup. The System can be used for oily sludge to recover the remaining oil and bitumen for processing.
Below is a partial list potential waste streams that can be treated:
Slop Oil and Battery Wastes such as, mixes of puddings, produced water, emulsified oil and solids. By removing the water and the solids we create a usable product which presents an opportunity for recovering lost revenue.
We separate the oil, water and liquid residues using the DryVac process. The oil can be sold. The recovered solids can be reused or disposed of based on circumstances and preference. Water, which is present, can be reclaimed as process water. Transportation and waste handling and dumping fees are dramatically reduced causing immediate financial benefits to the company.
Drilling wastes, using the DryVac technology, clean water can be returned for process use. The dried solids can be transported with fewer trucks at a reduced cost. What was previously a lost resource can be a recoverable product.
Additionally, the dried solid material can be converted into a delisted product which can be recovered for pad work and road base material. The impact of previously dealing with these wastes on the environment is severely reduced.
With this process;
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